Advanced Gun Barrel Technologies (AGBT) Background and Results. NDIA Joint Armaments Conference, 2010

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Advanced Gun Barrel Technologies (AGBT) Background and Results NDIA Joint Armaments Conference, 2010 Presented by: Mr. Bill Vezina BAE Systems, Inc. Land & Armaments william.vezina@baesystems.

1 Advanced Gun Barrel Technologies (AGBT) Background and Results NDIA Joint Armaments Conference, 2010 Presented by: Mr. Bill Vezina BAE Systems, Inc. Land & Armaments (763) Office of Naval Research Program Manager: Mr. Dan Simons Technical Direction Agent: Mr. Paul Conolly BAE Systems, Land & Armaments Program Manager: Dr. Amir Chaboki Technical Lead: Mr. Mike Hermanson

2 Outline AGBT program background Development approach Technology selection and screening Subscale development and testing Full scale firing demonstration Summary and conclusion Questions

Objectives - Identify & develop Gun Barrel Technologies that enable upgrades to existing barrel capabilities for Naval gun propulsion missions 50% increase in Gun Barrel Erosion & Fatigue Life

3 Objectives - Identify & develop Gun Barrel Technologies that enable upgrades to existing barrel capabilities for Naval gun propulsion missions 50% increase in Gun Barrel Erosion & Fatigue Life Reduced Life Cycle Cost Improved Gun Barrel Thermal and Ballistic Performance Payoffs - Increased Gun System Availability - Improved Ballistic Capability (Higher KE for increased range) - Lower Life Cycle Cost Transition Advanced Gun Barrel Technologies ONR Future Naval Capabilities Program - Demonstrate Improved Barrel Life and Ballistic performance over AGS Baseline for Transition into DDG 1000

Large Caliber Naval Guns MK 45 / Mod. 2 Bore: 5-inch (127mm) Length: 54cal, 22.5 ft (6.

with various projectiles Muzzle energy: 10 MJ MK 45 / Mod. 4 Bore: 5-inch (127mm) Length: 62cal, 25.8 ft (7.

Projectile/Propelling Charge (under development) Muzzle Energy: 18 MJ Advanced Gun System (AGS) Bore: 155mm (6.1 in) Length: 62cal, 31.5 ft (9.

4 Large Caliber Naval Guns MK 45 / Mod. 2 Bore: 5-inch (127mm) Length: 54cal, 22.5 ft (6.9m) Operating Pressure: 55 kpsi (380 MPa) Range: 13 Nmi Volume of Fire: rnds/min (20 round ready service) Barrel Life: 8000 rnds Thermal Mgmt: Air Cooling Mark 67 charge with various projectiles Muzzle energy: 10 MJ MK 45 / Mod. 4 Bore: 5-inch (127mm) Length: 62cal, 25.8 ft (7.9m) Operating Pressure: 63 kpsi (435 MPa) Range: 41 Nmi Volume of Fire: 8-10 rnds/min (10 round ready service) Barrel Life: 1,500 rnds Thermal Mgmt: Air Cooling ERM Projectile/Propelling Charge (under development) Muzzle Energy: 18 MJ Advanced Gun System (AGS) Bore: 155mm (6.1 in) Length: 62cal, 31.5 ft (9.6m) Operating Pressure: 53 kpsi (365 MPa) Range: 83 Nmi Volume of Fire: 10 rnds/min Sustained Barrel Life: 3,000 rnds (Req.) Thermal Mgmt: Liquid Cooling Long Range Land Attack Projectile/Propelling Charge Muzzle Energy: 27 MJ Trend toward higher performance guns using more aggressive propellants Increased performance levels result in barrel life becoming a logistics cost driver

Current Technology: Hard Chrome Root Problem: Chrome Plated Barrel Wear and Erosion Thermally induced

chemical attack of steel from combustion gasses undermines chrome Chrome islands are jeopardized until they

Steel substrate is rapidly eroded by high velocity combustion gasses and accelerated chemical attack at

5 Current Technology: Hard Chrome Root Problem: Chrome Plated Barrel Wear and Erosion Thermally induced stresses create heat check cracks during firing Underlying substrate is thermally altered (HAZ) Subsequent chemical attack of steel from combustion gasses undermines chrome Chrome islands are jeopardized until they break free and leave steel substrate exposed. Steel substrate is rapidly eroded by high velocity combustion gasses and accelerated chemical attack at high temperatures. Bore scope view of heat checks at origin of rifling Heat Check Cracks Chrome Plate Heat Affected Zone (HAZ) Chemical attack at high temperature undermines chrome

6 AGBT Development Approach Identify existing technologies that have the potential to improve the service life of large caliber gun barrels and can be developed into full scale (155mm) process capability within the time frame of the program Screen these technologies using actual gun firings rather than vented combustors or other accelerated wear tests Select the most promising technologies for additional evaluation in a high rate of fire environment Identify the single best performing technology and demonstrate its performance in full scale 155mm test firings

AGBT Development Approach Primary Program Phases I.

Screen these technologies through firing tests in a scaled down large caliber gun environment. II.

Select the best technology and demonstrate its performance in a full scale 155mm high rate of fire environment.

7 AGBT Development Approach Primary Program Phases I. Identify currently available technologies that offer the potential to extend the life and performance of large caliber gun barrels. Screen these technologies through firing tests in a scaled down large caliber gun environment. II. Select the two most promising technologies for a competitive shoot-off in a medium caliber high rate of fire environment. III. Select the best technology and demonstrate its performance in a full scale 155mm high rate of fire environment. Technology Assessment Electroless Nickel-Boron Sputtering Explosive Cladding CED EPVD 45mm Screening Evaluations Subscale Competition/Demo Explosive Cladding EPVD Chrome Plating 76mm Gun Tests 155mm Prototype Demonstration EPVD 155mm AGS Gun Tests Free Form Fabrication 45mm Laboratory Gun Fixture MK75 76mm Naval Gun AGS 155mm EDM Gun Mount

8 Technology Selection and Screening Various coating technology vendors were identified Vendors of promising technologies were selected to perform under sub-contract Vendors applied their coating technology to an insert that was assembled into the shot start region of the 45mm test gun Each insert was subjected to a 50 shot test series Adhesion results compared to a chrome plated insert baseline using micrographic analysis

Candidate Coating Technologies Electroless Nickel-Boron Sputtering Plasma (Ionized Inert Gas) Explosive Cladding Plasma Power Supply + 300V - I Substrate (Gun Tube) I COLLISION Ar e I e - e I - Ar+ e

9 Candidate Coating Technologies Electroless Nickel-Boron Sputtering Plasma (Ionized Inert Gas) Explosive Cladding Plasma Power Supply + 300V - I Substrate (Gun Tube) I COLLISION Ar e I e - e I - Ar+ e - Magnetic Ta Field Lines, B + - I 10V Target Power Supply I GND Target (Cathode) I Catalytic plating process produces extremely uniform coating even on complex geometries Coaxial Energetic Deposition Material is sputtered, from a coaxial target, uniformly over the inside diameter of the barrel Electromagnetically Enhanced Physical Vapor Deposition Tube of cladding material is mechanically bonded with the gun barrel in a collision driven by an explosive detonation Solid Free-Form Fabrication Plasma arc rotates around center conductor and travels along its length depositing material Electrically controlled magnetic fields enhance the plasma environment of the physical vapor Engineered material is created by alloying of powdered and/or wire-fed metals

Technology Screening Platform 45mm Test Gun 7.

inserts screened: (6) Technology candidates (1) Chrome baseline 3.

gun 45mm ballistics designed to reproduce thermal, chemical and mechanical

coating adhesion and integrity Screening Test Winners: Explosive Cladding and

10 Technology Screening Platform 45mm Test Gun 7.4 kg projectile 45mm/67 caliber smoothbore barrel 45mm Rifled Test Insert Qty of inserts screened: (6) Technology candidates (1) Chrome baseline 3.0 liter chamber Coated Insert Coated insert assembled at shot start region of gun 45mm ballistics designed to reproduce thermal, chemical and mechanical environment of a large caliber gun 50 shot test sequences used to evaluate coating adhesion and integrity Screening Test Winners: Explosive Cladding and EPVD 45mm gun in place at BAE Systems test range Provided a cost effective method for evaluating coatings prior to large caliber gun evaluation

11 Explosive Cladding Process

12 EPVD Process (Electromagnetically Enhanced PVD) Electromagnetically Enhanced Physical Vapor Deposition (EPVD ) Uniform thickness on lands and grooves

13 76mm Medium Caliber Testing 76mm platform selected for similar match to the AGS near bore thermal profile Historical 76mm service records indicated that measurable wear and erosion would occur within 400 rounds fired Technologies were applied to the bore of MK 75 gun barrel liners for firing at rate for a total of 400 rounds each. A chrome plated baseline liner was subjected to the same test. 76mm tests were conducted at the Naval Surface Warfare Center, Dahlgren Division (NSWCDD). Prototype Barrel Assembly For Mk 75 76mm Gun

EPVD coated liner were subjected to 400 rounds each, at max rate of fire in Mk 75 Naval gun Each liner

14 76mm Rapid Fire Testing Explosive clad liner experienced problems in manufacturing that were not recoverable within the time frame of this program and therefore effort was ceased Chrome Baseline and EPVD coated liner were subjected to 400 rounds each, at max rate of fire in Mk 75 Naval gun Each liner was subjected to ten 40 round bursts at ~90 rounds per minute Detailed inspections conducted every 80 rounds

rifling area EPVD Ta-W Moderate erosion exists in the Origin of Bore area In both cases, coating removal from

15 76mm Post Test Inspection Baseline Chrome Plating Shot Start Region Chamber Case Mouth NSWCDD bore scope reports at conclusion of test Baseline Chrome Heavy erosion is present in the origin of bore and origin of rifling area EPVD Ta-W Moderate erosion exists in the Origin of Bore area In both cases, coating removal from lands is due to engraving loads of gilding metal rotating bands. EPVD erosion much less than Chrome EPVD Ta-W Plating

coating layer without apparent cracking or obvious heat affected zone EPVD

16 Micrographic View of Coatings Chrome plating shows significant heat check damage with cracks extending up to 1mm deep in substrate EPVD shows a thicker coating layer without apparent cracking or obvious heat affected zone EPVD applied Ta-W coating was well adhered and provided excellent thermal and chemical protection

Full-Scale 155mm Demonstration Full scale tests conducted using the BAE Systems Advanced Gun System (AGS) Engineering Development Model (EDM) mount at Dugway

17 Full-Scale 155mm Demonstration Full scale tests conducted using the BAE Systems Advanced Gun System (AGS) Engineering Development Model (EDM) mount at Dugway Proving Grounds, Utah A multi-piece 155mm barrel was used for AGS rapid fire testing Barrel was subjected to Proof shots as well as extended firing at 10 rounds per minute

18 Tube and Liner Barrel Assembly AGBT test barrel is a tube and liner assembly Liner is a multi-piece subassembly Allowed barrel to be fabricated from available assets Allowed barrel to be coated using existing equipment Integrates with the EDM mount using existing cooling hardware

19 Advanced Gun System (AGS) 155mm (6.1 ) 62 cal. 10 rounds/min. Vertical load Liquid cooled All electric drives Fully Automated Magazine 61 total shots fired in AGBT test series 155mm Development

Shot 0 Coating delaminated in noted area

delaminated area grew slightly Shot 61 At

20 Shot 0 Coating delaminated in noted area prior to firing Laser Scan data of Shot Start Region Note: area of delamination Shot 8 At conclusion of proof series, delaminated area grew slightly Shot 61 At conclusion of rapid fire series, minimal additional grown.

Degree of coating loss Localized area at origin of rifling shows loss of the upper most layer(s) of the

Damaged area does not grow appreciably during the firings Laser based profilometry used to determine depth of

0025 deep Substrate is not exposed, damage appears limited to top layer(s) Barrel not removed for micrographic

21 Degree of coating loss Localized area at origin of rifling shows loss of the upper most layer(s) of the coating in three adjacent grooves prior to firing. Damaged area does not grow appreciably during the firings Laser based profilometry used to determine depth of features. Accuracy: +/ Full depth of coating is.005 thick Coating delamination: ~.0025 deep Substrate is not exposed, damage appears limited to top layer(s) Barrel not removed for micrographic analysis of coating. Shot 0 Shot 8 ~.0025 Δ ~.0025 Δ Conclusion: EPVD coating adhesion to barrel substrate held-up during firing tests. Work still needed to address inter-coating delamination Shot 61

22 Summary and Conclusions AGBT Program successfully met objectives Selected technology: EPVD Improvements in coating composition needed to tolerated mechanical engraving loads of gilding metal rotating bands Improvements in processing needed to address interlaminar adhesion Application of EPVD technology for gun barrel use is relatively new. Potential for different compositions of various materials exists BAE Systems is currently working with the U.S. Navy to transition this technology for fleet use

23 Questions For additional information, please contact: Bill Vezina BAE Systems, Inc. Land and Armaments (763)

Advanced Gun Barrel Technologies Program Status

Advanced Gun Barrel Technologies Program Status Dr. Amir Chaboki United Defense NDA Guns -Ammunition - Rockets - Missiles Conference 28 April 2005 FNC227.ppt - Page 1 Large Caliber Naval Guns MK 45 / Mod.